8D PROBLEM SOLVING

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Presentation by Senthilkumar RM 8D Invention Ford Motor Company started a problem solving process known as 8D which takes 8 Disciplines and uses them to tackle engineering problems

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Presentation by Senthilkumar RM Why to Go ? To Eliminate the cause of Detected Non conformity To protect the customer from receiving or using nonconforming product Corrective action is taken to prevent recurrence

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Presentation by Senthilkumar RM Why 8D ? 8D is a structured approach to solving problems Fact Based Data Collection & Analysis Tests progress and results Verify & Validate Documented History – An information database Anticipate future problems Prevent recurrence

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Presentation by Senthilkumar RM 8D Flow

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Presentation by Senthilkumar RM D0 : Recognize the problem Determining the structure of a problem assists in the selection of the correct tools to use. It may give clues to the nature of the root causes

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Presentation by Senthilkumar RM D0 : Continued ..

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Presentation by Senthilkumar RM D1 : Establish Team Establish a small group of people with the knowledge, time, authority and skill to solve the problem and implement corrective actions. The group selects a team leader Cross Functional or Multi-Disciplinary Process Owner Technical Expert Others involved in the containment, analysis, correction and prevention of the problem

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Presentation by Senthilkumar RM D2 : Problem Description Problem statement = Object + concern + quantification Describe the problem in measurable terms. Specify the internal or external customer Remember: A well defined problem is half solved!

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Presentation by Senthilkumar RM D3 : Containment Action Define and implement those intermediate actions that Will protect the customer from the problem until permanent corrective action is implemented. Verify with data the effectiveness of these actions.

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Presentation by Senthilkumar RM D4 : Identify Root Cause Identify potential causes which could explain why the problem occurred. Test each potential cause against the problem description and data. Identify alternative corrective actions to eliminate root cause. Tools Used - 5Why ; Fishbone ; Scatter

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Presentation by Senthilkumar RM D5 : Choose and verify Corrective action After root causes and possible corrective actions have been identified, select the corrective actions that will permanently correct the problem. Decision analysis may be needed if the choice is not obvious. Verify that the selected corrective actions will resolve the problem Tools used : Poke – Yoke

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Presentation by Senthilkumar RM D6 : Implement and Validate CA Implementation can proceed when best corrective action has been selected & verified. An effective implementation plan reduces problems. Validation is obtained by tracking performance over time after implementation to ensure the corrections are permanent.

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Presentation by Senthilkumar RM D7 : Prevent System Recurrence Implement the corrective actions in other potentially affected areas Ensure the systems that allowed the problem to occur and escape have been corrected The problem is now Solved & requiring a larger scale continual improvement project of some type

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Presentation by Senthilkumar RM D8 : Congratulate the Team Recognize the collective efforts of your team. Publicize your achievement. Share your knowledge and learning.

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Presentation by Senthilkumar RM Quick Ponder !! What is D Stands for in 8D? Who invented in 8D? Title 8D ? Thank you all !!